Modern automation demands more than simple on-off switches. Whether you're designing a motorized TV lift, automating camper van storage, or building custom smart furniture, you need precise control, reliable operation, and the flexibility to manage your system remotely. The challenge has always been bridging the gap between simple wireless control and professional-grade actuator management — until now.
🎥 Video — How to Control Linear Actuators Over WiFi Using the MHCOZY Relay and FIRGELLI FCB-2 Controller
This comprehensive guide demonstrates how to integrate the MHCOZY WiFi relay with FIRGELLI's FCB-2 controller to create a sophisticated actuator control system that you can operate from anywhere in the world. We'll cover both basic direct-wiring configurations and advanced multi-actuator setups that deliver synchronization, speed control, programmable limits, and precise positioning — all without requiring custom programming or complex electronics knowledge.
By the end of this guide, you'll understand exactly how to build a professional-quality automation system that combines the convenience of wireless smartphone control with the precision and reliability required for demanding applications. Whether you're a hobbyist building your first motorized project or an engineer designing a commercial installation, this integration approach offers the performance and flexibility you need.
Understanding WiFi Relay Control Basics
Before diving into the wiring details, it's important to understand what a WiFi relay actually does in an actuator control system. At its core, the MHCOZY WiFi relay functions as an electronically-controlled double-pole double-throw (DPDT) switch that you can trigger remotely through a smartphone app, RF remote, or even voice commands through smart home platforms.
When you send a command through the Smart Life app, the relay changes its internal contact configuration, reversing the polarity of power delivered to your linear actuator. This polarity reversal is what causes the actuator to extend or retract. The relay essentially replaces a traditional rocker switch or momentary push-button with a wireless control interface.
The MHCOZY relay supports both WiFi connectivity (allowing control over your local network or through the cloud) and RF remote operation, providing redundant control methods. This dual-mode capability is particularly valuable in applications where WiFi connectivity might be intermittent or where you want both app-based and physical remote control options.
Direct Actuator Wiring Configuration
The simplest implementation connects the MHCOZY relay directly to a linear actuator, creating a basic wireless control system. This configuration is ideal for single-actuator applications where you need straightforward extend and retract functionality without advanced features like speed adjustment or electronic limit setting.
Wiring Steps: Basic Setup
To wire the MHCOZY directly to your actuator, connect the actuator's motor wires to the two output terminals on the relay. Most linear actuators have two motor wires (typically red and black) that connect to these terminals. Polarity at this stage doesn't matter — the relay will handle direction control by switching polarity internally.
Next, connect a suitable DC power supply to the relay's power input terminals. The voltage should match your actuator's rated voltage, typically 12V or 24V DC. Ensure your power supply can deliver sufficient current for your actuator's load requirements — undersized power supplies will cause sluggish performance or premature failure.
Finally, configure the MHCOZY using the Smart Life app on your smartphone. The app will guide you through connecting the relay to your WiFi network and setting up control buttons. Once configured, you can extend and retract the actuator with a tap on your phone or press of the included RF remote.
Limitations of Direct Connection
While this direct connection provides convenient wireless control, it has significant limitations for serious automation projects. You cannot adjust actuator speed, set custom stroke lengths, or synchronize multiple actuators. The actuator will run at full speed until it reaches its mechanical limit switches or until you release the button — there's no way to stop at precise positions or create soft-start/soft-stop motion profiles.
Additionally, without feedback control, if you're operating multiple actuators (such as in a dual-actuator TV lift or four-corner lifting platform), they will inevitably fall out of sync due to minor variations in load, friction, and manufacturing tolerances. This can cause binding, uneven motion, and premature wear.
For these reasons, direct wiring is best suited to simple single-actuator applications like small access panels, simple lid lifts, or basic linear motion tasks where precise control isn't critical.
Advanced Control with FCB-2 Integration
The real power of WiFi actuator control emerges when you integrate the MHCOZY relay with FIRGELLI's FCB-2 controller. This combination preserves the convenience of wireless smartphone control while adding professional-grade features that dramatically expand what your actuator system can do.
In this configuration, the MHCOZY relay doesn't power the actuator directly. Instead, it sends control signals to the FCB-2 controller, which then manages power delivery to up to four actuators simultaneously. Think of the MHCOZY as providing the "brain" for remote control decisions, while the FCB-2 serves as the sophisticated "muscles" that execute those commands with precision.
Wiring the Integrated System
Begin by connecting your linear actuators to the M1 through M4 motor terminals on the FCB-2 controller. Each pair of terminals (M1+/M1-, M2+/M2-, etc.) connects to one actuator. If your actuators include feedback capabilities — either Hall effect sensors or potentiometric position sensing — connect these feedback wires to the corresponding sensor terminals on the FCB-2.
Next, wire the MHCOZY relay's output terminals to the FCB-2's switch input terminals, typically labeled UP and DOWN or EXT/RET. These are low-voltage signal inputs that tell the FCB-2 when to extend or retract the connected actuators. The MHCOZY's relay contacts close these circuits just as a physical push-button would, but you're triggering them wirelessly.
Power both the MHCOZY and FCB-2 from the same DC power supply, ensuring it's rated for the combined current draw of all your actuators plus the controller's own consumption. For systems with multiple high-force actuators, you may need a power supply rated for 10-20 amps or more, depending on your specific actuators' current requirements.
Configuration and Programming
The FCB-2 controller uses a straightforward menu-driven interface accessed through its included handheld remote. You can set numerous parameters without any computer programming:
- Speed Control: Adjust actuator speed from 0-100%, allowing you to optimize for quiet operation, smooth motion, or maximum speed depending on your application
- Stroke Length Limits: Electronically define how far each actuator extends, eliminating the need for mechanical limit switches and allowing you to change limits on the fly
- Synchronization Settings: When using feedback actuators, enable the sync function to keep multiple actuators moving in perfect unison regardless of load variations
- Timer Functions: Program automatic cycles, delay timers, and timed movement sequences for applications requiring repeated motion patterns
- Soft Start/Stop: Enable ramped acceleration and deceleration to reduce mechanical shock and extend actuator service life
Once configured, the FCB-2 stores these settings in non-volatile memory, so they persist through power cycles. You can then control the system through the MHCOZY's Smart Life app, the FCB-2's handheld remote, or both — whichever is most convenient for the situation.
Key Features Unlocked by FCB-2 Integration
The FCB-2 controller transforms a basic actuator into a sophisticated positioning system. Understanding these capabilities helps you design more capable automation projects and avoid the limitations of simpler control approaches.
Precision Synchronization
When you connect feedback actuators to the FCB-2, the controller continuously monitors the position of each actuator and adjusts motor power to keep them synchronized. This is critical for applications like lifting platforms, large doors, or adjustable furniture where uneven motion causes binding or cosmetic issues.
The synchronization algorithm accounts for real-time load variations, friction differences, and manufacturing tolerances. If one actuator starts to lag — perhaps because it's carrying more weight or experiencing higher friction — the controller automatically reduces power to the faster actuator until positions equalize. This dynamic adjustment happens continuously during motion, maintaining alignment within millimeters even across stroke lengths of 500mm or more.
Programmable Electronic Limits
Traditional actuators rely on mechanical limit switches that physically cut power when the actuator reaches its fully extended or retracted position. While functional, these mechanical switches have several drawbacks: they're fixed at the factory, they create hard stops that generate shock loads, and they're another mechanical component that can fail over time.
The FCB-2's electronic limit feature eliminates these issues when used with feedback actuators. You can set precise start and stop positions anywhere within the actuator's stroke range, effectively creating a "virtual" shortened stroke. This is invaluable when your application doesn't require the actuator's full travel or when you need to avoid obstacles at certain positions.
Because limits are electronic, you can reprogram them instantly without any mechanical adjustments. If your application requirements change, simply adjust the limit values in the FCB-2's menu rather than disassembling the mechanism to reposition limit switches.
Adjustable Speed Control
Speed control serves multiple purposes in actuator applications. Slower speeds reduce noise — critical for TV lifts and bedroom furniture applications. Slower speeds also reduce vibration transmission to the mounting structure and create smoother, more refined motion that appears higher quality to end users.
The FCB-2 implements speed control through pulse-width modulation (PWM) of the motor power. This electronic speed control is far superior to simply reducing voltage, which would cause the actuator to stall under load. With PWM control, the actuator maintains full torque capability even at reduced speeds, ensuring reliable operation regardless of the speed setting you choose.
Different parts of a motion sequence can use different speeds. You might configure rapid movement through the middle of the stroke for efficiency, then automatically slow down as the actuator approaches its limits for quiet, controlled arrival at the end positions.
Timer and Automation Functions
The FCB-2 includes several timer-based functions that enable automated operation without external controllers. The auto-cycle function, for example, can repeatedly extend and retract actuators at programmed intervals — useful for agitating mechanisms, periodic ventilation systems, or testing fixtures.
Delay timers allow you to sequence multiple groups of actuators. You might extend one set of actuators, wait a defined period, then extend a second set — all triggered by a single input from your MHCOZY relay. This sequencing capability is valuable in complex mechanisms where simultaneous motion would cause interference or excessive current draw.
Application Examples and Use Cases
Understanding the practical applications helps contextualize how this integrated control system solves real automation challenges. These examples demonstrate both the versatility of the MHCOZY/FCB-2 combination and the considerations for different application types.
Motorized TV Lifts
Hidden TV lifts represent one of the most demanding actuator applications. They require synchronized dual-actuator operation to keep the TV level during motion, quiet operation for bedroom or living room use, and smooth speed control for refined motion quality. The integrated system delivers all these requirements while adding smartphone control for convenience.
Using two feedback actuators connected to the FCB-2 ensures the TV remains perfectly level throughout its travel. Speed can be set to 40-60% for quiet operation, and soft start/stop eliminates the jarring mechanical shock of sudden starts. The MHCOZY allows you to trigger the lift from your phone, RF remote, or integrate it with home automation systems for voice control through Alexa or Google Home.
RV and Camper Automation
Recreational vehicles and camper vans increasingly use linear actuators for beds, roof vents, storage compartments, and slide-outs. The MHCOZY's compact form factor and wireless control are ideal for retrofit installations where running control wiring through finished interiors is impractical.
The FCB-2's electronic limits are particularly valuable in RV applications where physical space constraints may prevent using an actuator's full stroke. You can precisely define the available travel without mechanical modifications, and the synchronization capability ensures large panels or beds remain level despite the vehicle's uneven weight distribution.
Industrial Access Panels and Hatches
Industrial environments often require remote operation of access panels for safety or operational efficiency. The MHCOZY/FCB-2 combination provides reliable industrial-grade control while allowing operators to trigger motion from safe distances or from control rooms.
When using industrial actuators rated for harsh environments, the system can control heavy hatches with multiple synchronized actuators. The timer functions enable automated opening/closing cycles for processes requiring periodic access, and the ability to adjust speed allows operators to balance cycle time against noise and vibration considerations.
Smart Furniture and Adjustable Workstations
Height-adjustable desks, motorized recliners, and adjustable beds benefit from the refined motion control and smartphone integration this system provides. Multiple height presets can be configured using the FCB-2's position memory when paired with feedback actuators, allowing users to save and recall preferred positions.
The wireless control aspect means no dangling control boxes or wired remotes — particularly valuable for furniture applications where aesthetics matter. Users can adjust position from across the room, and the system can integrate with existing smart home ecosystems for voice control or automation routines.
Selecting Compatible Actuators
Not all actuators offer the same capabilities, and choosing the right actuator type significantly impacts what features you can implement. Understanding actuator categories and specifications ensures your system delivers the performance your application requires.
Feedback vs. Non-Feedback Actuators
Feedback actuators include internal position sensing — either Hall effect sensors that count magnetic pole transitions or potentiometric sensors that provide continuous voltage-based position signals. These feedback signals allow the FCB-2 to know each actuator's exact position at all times, enabling synchronization, electronic limits, and position memory features.
Non-feedback actuators are less expensive but can only be controlled in basic extend/retract modes. When connected to the FCB-2, they gain speed control and timer functions, but not position-based features. For simple single-actuator applications, non-feedback units may be adequate, but any application requiring precision or multi-actuator coordination benefits from feedback-equipped models.
Force and Speed Specifications
Actuator force ratings typically range from 50 lbs to over 2,000 lbs, with higher force actuators generally operating at slower speeds due to gear reduction requirements. Calculate the actual force requirements for your application, accounting for friction, angle of installation (actuators mounted at angles produce reduced effective force), and any dynamic loads during motion.
Speed specifications are typically given in millimeters per second or inches per second at no load. Actual speed under load will be slower, and the FCB-2's speed control further modulates this. For applications requiring both high force and high speed, consider track actuators, which use a guided carriage design that can deliver higher speeds at substantial force levels.
Stroke Length Considerations
Stroke length — the total distance the actuator can travel — should be selected based on your mechanism's required range of motion plus a small safety margin. Common stroke lengths range from 50mm (2 inches) for compact applications up to 1000mm (40 inches) or more for large-scale mechanisms.
Remember that the actuator's retracted length is approximately twice the stroke length (due to the tube-within-tube telescoping design), so ensure you have adequate space in your mechanism's retracted position. The FCB-2's electronic limit feature means you can choose a longer stroke actuator than strictly necessary and simply limit the used range electronically, providing flexibility for design changes.
Environmental Ratings
For outdoor installations, marine environments, or industrial settings with washdown requirements, select actuators with appropriate IP (Ingress Protection) ratings. IP66-rated actuators provide protection against powerful water jets and complete dust protection, suitable for most outdoor applications. For submersible applications or extreme environments, IP68 or IP69K ratings may be necessary.
Standard linear actuators typically carry IP54 ratings, adequate for indoor use and protected outdoor installations. The FCB-2 controller itself is designed for protected installation and should be mounted inside enclosures for outdoor use.
Power Supply Sizing and Electrical Considerations
Proper power supply selection is critical for reliable system operation. Undersized supplies cause voltage sag under load, resulting in slow actuator motion, controller resets, or complete system failure. Oversized supplies waste money but don't harm system operation, so when in doubt, size up.
Calculating Current Requirements
Each actuator's current draw varies with force output and speed. Typical 12V actuators draw 2-6 amps depending on load, while higher force units may draw 10 amps or more. The actuator datasheet provides current specifications, usually given at no load and at maximum rated load.
For multi-actuator systems, calculate total current by summing the maximum current draw of all actuators, then add 20% margin for startup surge currents and controller consumption. A system with four actuators drawing 4 amps each would require: (4 actuators × 4 amps) × 1.2 = 19.2 amps, suggesting a 20-25 amp power supply for safe operation.
Voltage Selection
Most FIRGELLI actuators operate at either 12V or 24V DC. Higher voltage systems have advantages for longer wire runs and higher power applications because they draw less current for the same power level, reducing voltage drop in wiring and allowing smaller gauge wire.
The MHCOZY relay and FCB-2 controller both support 12V-24V operation, so your voltage choice is primarily driven by actuator selection and application requirements. For automotive or RV applications, 12V is standard due to available vehicle power. For industrial or custom installations, 24V often provides better performance.
Wiring Gauge and Protection
Wire gauge must be adequate for the current being carried and the distance from power supply to actuators. For 12V systems, use 14 AWG wire for runs up to 15 feet at 10 amps, or 12 AWG for higher currents or longer distances. Undersized wire causes voltage drop that reduces actuator performance and creates fire hazards.
Include appropriate fusing or circuit breaker protection sized slightly above your system's maximum expected current draw. This protects against wiring faults and actuator failures. Place the protection device as close to the power supply as practical to protect the entire circuit.
Installation Best Practices
Proper mechanical installation is as important as correct electrical wiring. Even with perfect electrical setup, poor mechanical design causes premature failure, binding, and unsatisfactory performance.
Mounting and Alignment
Actuators must be mounted so that motion occurs along a single axis without side loading. The telescoping shaft should move perfectly parallel to the actuator body throughout the entire stroke. Any angular deviation creates bending loads that cause premature bushing wear and eventual mechanical failure.
Use appropriate mounting brackets that allow pivoting at both actuator ends. This accommodates the slight changes in angle that occur as linkages move. Rod-end bearings or clevis mounts work well, while rigid bolted connections should be avoided unless the mechanism geometry ensures perfect alignment.
When installing multiple synchronized actuators, ensure they're mounted symmetrically with equal load distribution. Asymmetric installations create unequal forces that the synchronization system must compensate for, reducing efficiency and potentially exceeding the controller's adjustment range in extreme cases.
Cable Management
Actuator cables, particularly feedback wires, should be secured and protected from abrasion or pinching during motion. Use cable carriers or flexible conduit for moving connections. Allow sufficient slack so cables don't pull tight at full extension, but avoid excess slack that can catch on mechanism components.
Separate power wiring from control signal wiring where possible to minimize electromagnetic interference, particularly important in installations near radio equipment, WiFi routers, or variable-frequency drives. Twisted-pair wiring for feedback signals improves noise immunity.
Environmental Protection
Even with IP-rated actuators, protect connectors and the FCB-2 controller from direct moisture exposure. Mount the controller in a NEMA-rated enclosure for outdoor installations. Ensure drainage paths exist so water cannot pool around actuators or control equipment.
For installations in high-vibration environments, use threadlocker on mechanical fasteners and add vibration-dampening mounts where appropriate. Check and retighten connections during initial operation period, as vibration can loosen hardware during the first hours of use.
Troubleshooting Common Issues
Understanding common problems and their solutions helps you diagnose and resolve issues quickly, minimizing downtime and avoiding unnecessary component replacement.
Actuators Not Responding to WiFi Commands
First verify the MHCOZY relay itself is functioning by checking its LED indicators and testing with the included RF remote. If the relay responds to RF but not WiFi commands, the issue is network connectivity — check that the relay remains connected to your WiFi network in the Smart Life app.
If the relay operates but actuators don't respond, verify wiring between the MHCOZY and FCB-2 controller. The relay contacts must be wired to the correct input terminals on the FCB-2. Test by manually triggering these same inputs with a momentary switch to confirm the FCB-2 responds to those inputs.
Synchronization Drift
If multiple actuators gradually fall out of sync despite using feedback actuators and enabling sync mode, verify that feedback wiring is correct and secure. Intermittent feedback connections cause position errors. Also confirm that all actuators are the same model with identical gear ratios and feedback types — mixing different actuator models prevents accurate synchronization.
Extreme load imbalance can exceed the controller's synchronization compensation range. If one actuator carries significantly more weight, the controller may not be able to slow it sufficiently to maintain sync. Rebalance loads or select higher-force actuators for the more heavily loaded positions.
Slow or Weak Actuator Motion
Slow motion under load typically indicates inadequate power supply voltage or current capacity. Measure actual voltage at the FCB-2 input terminals during actuator operation — if voltage drops below 11V on a 12V system (or 22V on a 24V system), the power supply is undersized or wiring has excessive resistance.
Check the FCB-2 speed setting, which may have been inadvertently reduced. Also verify that the actuator isn't mechanically binding due to misalignment or obstruction. An actuator drawing excessive current indicates mechanical resistance that should be corrected rather than compensated for with more power.
Erratic Behavior or Random Triggering
Intermittent operation often results from loose wiring connections. Check all terminals, particularly crimp connections and screw terminals, ensuring they're tight and making good electrical contact. Vibration can loosen connections over time.
Electromagnetic interference from nearby motors, fluorescent lighting, or switching power supplies can cause false triggering. Relocate the MHCOZY and FCB-2 away from these sources if possible, or add ferrite cores to power and control cables to suppress high-frequency interference.
Expanding System Capabilities
Once you've implemented the basic MHCOZY/FCB-2 system, several expansion options allow even greater functionality for advanced applications.
Integrating Position Presets
When using feedback actuators, the FCB-2 can store multiple position presets — saved positions that the system can automatically return to with a single command. This transforms a simple extend/retract system into a multi-position system ideal for adjustable furniture or machinery with multiple operating configurations.
Program presets using the FCB-2's menu system, then trigger specific presets by momentarily closing different input terminals. The MHCOZY relay can trigger one preset; add additional relays or switches for more preset positions.
Sensor Integration for Automated Control
The FCB-2's input terminals can accept signals from external sensors, enabling automated responses to environmental conditions. A rain sensor could automatically close a motorized skylight, or occupancy sensors could raise a TV lift when someone enters the room.
These sensor inputs work in parallel with the MHCOZY relay control, allowing both manual wireless control and automated sensor-driven operation. The FCB-2 responds to whichever input is active, with programmable priority settings if multiple inputs are triggered simultaneously.
Voice Control Integration
Because the MHCOZY relay integrates with the Smart Life app ecosystem, it can be controlled through voice assistants including Amazon Alexa and Google Assistant. Set up virtual devices in your smart home platform corresponding to extend and retract commands, then control your actuators with voice commands.
This voice integration works well for accessibility applications, allowing people with mobility limitations to control their environment without physical switches. It's also valuable for hands-free operation when working on tasks that make reaching for a remote or phone inconvenient.
Why FIRGELLI Actuators and Controllers
The quality of your actuators and control hardware fundamentally determines your system's long-term reliability and performance. FIRGELLI Automations has engineered electric motion control systems for over two decades, with expertise rooted in automotive and aerospace applications where failure is not acceptable.
FIRGELLI linear actuators use precision-machined components, high-grade motors, and robust gearing that delivers consistent performance through millions of cycles. The company manufactures actuators across a comprehensive range — from compact micro linear actuators for small mechanisms to heavy-duty industrial actuators for demanding commercial applications.
The FCB-2 controller represents over 20 years of accumulated knowledge about what actuator control systems need to deliver in real-world applications. It provides industrial-grade reliability without industrial-grade complexity or cost, making professional capabilities accessible to hobbyists, custom builders, and engineers alike.
All FIRGELLI products are designed to work together as an integrated system. Actuators, controllers,
